Heritage HG02E Installation, Operating And Service Instructions

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Installation, Operating and Service Instructions for

HERITAGE

Models:

• HG02E

• HG03E

• HG04E

• HG05E

• HG06E

Manual Contents

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Pre-installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Removing Existing Boiler . . . . . . . . . . . . . . . . . 5

Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

System Start-Up and Checkout . . . . . . . . . . . 17

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Before Leaving Jobsite . . . . . . . . . . . . . . . . . . 23

Service and Maintenance . . . . . . . . . . . . . . . . 24

How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 30

Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

TO THE INSTALLER:

Affix these instructions adjacent to boiler.

Provide model number and serial number when

seeking information and support.

TO THE CONSUMER:

Retain these instructions for future reference.

Contact heating contractor for all issues and support.

Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury, or

loss of life. For assistance or additional information, consult a qualified installer, service agency or the gas

supplier. Read these instructions carefully before installing.

109445-01 - 6/19

Page

WARNING

• Water Boiler

• Cast Iron

• Chimney Vent

• Gas Fired

9700609

Table of Contents

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Summary of Contents for Heritage HG02E

Page 1: Table Of Contents
Installation, Operating and Service Instructions for HERITAGE • Water Boiler • Cast Iron • Chimney Vent • Gas Fired Models: • HG02E • HG03E • HG04E • HG05E • HG06E Manual Contents Page Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pre-installation .
Page 2 The City of New York requires a Licensed Master Plumber supervise the installation of this product. The Massachusetts Board of Plumbers and Gas Fitters has listed the Heritage E Boiler. See the Massachusetts Board of Plumbers and Gas Fitters website, http://license .reg .state .ma .us/pubLic/pl_products/pb_product .asp for the latest Approval Code or ask your local Sales Representative.
Page 3: Specifications
HERITAGE E Installation, Operating & Service Manual Specifications Table 1A: Ratings Boiler Model Number Input (MBH) DOE Heating Capacity (MBH) AHRI Net Rating (MBH) AFUE HG02E 84.0 HG03E 84.0 HG04E 84.0 HG05E 84.0 HG06E 84.0 Input ratings can be used for elevations up to 2,000 ft. Refer to Appendix: "High Altitude Installations" for installations above 2,000 ft.
Page 4: Pre-Installation
Do not install boiler where gasoline or other A. Heritage E boiler is Category I, draft hood flammable vapors or liquids are stored. Avoid equipped appliance with vent damper. areas near chemical products containing chlorine, B.
Page 5: Removing Existing Boiler
ANSI Z223.1/NFPA, or applicable provisions of for left side front jacket panels . local building codes. 2. Closet Installation - Models HG02E, HG03E, HG04E, HG05E & HG06E are listed for closet installation. See Figure 4-1. 3. Hot water pipes: at least 1/2" from combustible material.
Page 6 Installation, Operating & Service Manual HERITAGE E Clearances (continued) Model HG02E 6" 14" HG03E 6" 14" HG04E 6" 16" HG05E 6" 19" HG06E 6" 22" Figure 4-1: Minimum Closet Clearances Minimum radial clearance around draft hood and vent connector. ** Additional height required to maintain 6" clearance from all vent connector components. Vent damper may be installed in vertical or horizontal section of vent connector within reach of vent damper harness.
Page 7: Venting
ANSI Z223.1/NFPA 54, or applicable provisions hood skirt by locating center tooth (with of local building codes. The Heritage E boiler is a #10 sheet metal screw) on outside and Category I, draft hood equipped appliance with other two teeth inside draft hood skirt.
Page 8 Automatic gas control valve supplied on each 2. Vent pipes serving appliances vented by Heritage E boiler provides redundancy referenced natural draft shall not be connected into in vent damper Installation Instructions. any portion of mechanical draft systems operating under positive pressure.
Page 9 HERITAGE E Installation, Operating & Service Manual Venting (continued) G. Install vent termination (Masonry chimney and 2. For terminations located at least 8 ft. from single wall metal pipe) vertical wall or similar obstruction, termination shall extend above roof in accordance with 1.
Page 10: Water Piping
Installation, Operating & Service Manual HERITAGE E Water Piping C. Install safety relief valve. See Figure 6-1. Safety WARNING relief valve must be installed with spindle in Failure to properly pipe boiler may result in vertical position. improper operation and damage to boiler or building.
Page 11 HERITAGE E Installation, Operating & Service Manual Water Piping (continued) 109445-01 - 6/19...
Page 12 Installation, Operating & Service Manual HERITAGE E Water Piping (continued) 109445-01 - 6/19...
Page 13: Gas Piping
HERITAGE E Installation, Operating & Service Manual Gas Piping A. Size gas piping. Design system to provide adequate gas supply to boiler. Consider these factors: 1. Allowable pressure drop from point of delivery to boiler. Maximum allowable system pressure is ½ psig. Minimum gas valve inlet pressure is listed on rating label.
Page 14: Electrical
Installation, Operating & Service Manual HERITAGE E Electrical C. Wire boiler. Boiler is rated for 120 VAC, 60 HZ, WARNING less than 12 A. A separate electrical circuit must be run from the main electrical service with an Electrical Shock Hazard. Wiring errors can over-current device/disconnect in the circuit.
Page 15 HERITAGE E Installation, Operating & Service Manual Electrical (continued) Figure 8-1: Wiring Connection Diagram 109445-01 - 6/19...
Page 16 Installation, Operating & Service Manual HERITAGE E Electrical (continued) Figure 8-2: Schematic Ladder Diagram 109445-01 - 6/19...
Page 17: System Start-Up And Checkout
HERITAGE E Installation, Operating & Service Manual System Start-Up and Checkout A. Visual Main Burner Check 3. Isolate all circuits by closing zone valves Inspect burners for dislodgement during or turning off zone circulators. shipment. Rear of burners should be in vertical...
Page 18 Installation, Operating & Service Manual HERITAGE E System Start-Up and Checkout (continued) Figure 9-1: Operating Instructions 109445-01 - 6/19...
Page 19 HERITAGE E Installation, Operating & Service Manual System Start-Up and Checkout (continued) E. Perform gas leak test upstream of boiler shutoff 3. Locate and address leaks using listed valve. combustible gas detector,a non corrosive leak detection fluid or other listed leak 1.
Page 20 Installation, Operating & Service Manual HERITAGE E System Start-Up and Checkout (continued) J. Check Main Burner Flame (see Figure 9-5) valve can prevent pressure surge that blows out manometer fluid. 1. NORMAL FLAME: 2. Adjust regulator on gas valve so manifold a.
Page 21: Operation
HERITAGE E Installation, Operating & Service Manual Operation A. Temperature Limit/LWCO Control Refer to HydroStat 3200 Installation Instructions and Operating Manual included with these instructions. B. Electronic Ignition Module See Figure 10-1 for electronic ignition (EI). Electronic Ignition Modules with LED indicators.
Page 22 Installation, Operating & Service Manual HERITAGE E Operation (continued) v. Check pilot flame. It must be blue, h. Check pilot burner operation/ignition steady and envelop flame sensing sequence during ignition cycle: rod 3/8” to ½”. i. Restore boiler power at circuit vi.
Page 23: Before Leaving Jobsite
HERITAGE E Installation, Operating & Service Manual Before Leaving Jobsite Before Leaving Jobsite: Boiler and system filled with water  Performed gas leak test  Checked pilot burner flame  Checked main burner flames  Checked gas input rate ...
Page 24: Service And Maintenance
Installation, Operating & Service Manual HERITAGE E Service and Maintenance Important Product Safety Information: Refractory Ceramic Fiber Product WARNING Some boiler components use materials that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to elevated temperatures, RCF may change into crystalline silica, a known carcinogen.
Page 25 HERITAGE E Installation, Operating & Service Manual Service and Maintenance (continued) WARNING Service on this boiler should be undertaken only by trained and skilled personnel from a qualified service agency. Inspections should be performed at intervals specified in this manual. Maintain manual in a legible condition.
Page 26 Installation, Operating & Service Manual HERITAGE E Service and Maintenance (continued) D. Clean Main Burners and Firebox. Inspect Temperature/Pressure Gauge 1. To remove burners for cleaning, changing 1. Water temperature needle should move with orifices, or repairs: variation in water temperature.
Page 27 HERITAGE E Installation, Operating & Service Manual Service and Maintenance (continued) Q. Test Vent Damper Operation Vent damper must be in open position when main burners are operating. R. Test Functionality of LWCO See "Start-up and Checkout - Test LWCO Functionality.
Page 28: How It Works
HERITAGE E How It Works Heritage E boilers are equipped with Hydrostat 3200 and Honeywell S8610M Ignition module. Hydrostat 3200 contains features such as high limit switch, LWCO and circulator relay. Energy is saved by using a thermal target feature which adjusts boiler target temperature depending on heat required.
Page 29 HERITAGE E Installation, Operating & Service Manual How It Works (continued) 109445-01 - 6/19...
Page 30: Troubleshooting
Installation, Operating & Service Manual HERITAGE E Troubleshooting A. Before Troubleshooting When troubleshooting boiler, keep in mind: 1. Troubleshooting should be completed by a professional heating technician. 2. Before seeking technical assistance, the servicing technician should have an electrical meter and gas pressure gauge available for use.
Page 31 HERITAGE E Installation, Operating & Service Manual Troubleshooting (continued) "CALL FOR HEAT." POWER TO CHECK LINE VOLTAGE POWER, LOW VOLTAGE TRANSFORMER, LIMIT CONTROLLER, THERMOSTAT (CONTROLLER), AND WIRING. ALSO, MODULE? (24 V CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM (IF USED) AND THAT THE VENT DAMPER END SWITCH (IF USED) NOMINAL) IS MADE.
Page 32: Service Parts
Installation, Operating & Service Manual HERITAGE E Service Parts All Heritage service parts mat be obtained through TDC manufacturing Inc., 155 Route 61 South, Schuykill Haven, PA, 17972 Part Number [Quantity] Key No. Description HG02E HG03E HG04E HG05E HG06E 763907...
Page 33 HERITAGE E Installation, Operating & Service Manual Service Parts (continued) Part Number [Quantity] Description HG02E HG03E HG04E HG05E HG06E Base Wrapper Base Tray Burner Tray Assembly Base Side Insulation Base Rear Insulation Base Front Insulation 763918 763919 763920 763921 763922...
Page 34 Installation, Operating & Service Manual HERITAGE E Service Parts (continued) Part Number [Quantity] Description HG02E HG03E HG04E HG05E HG06E Gas Valve (Natural Gas), Honeywell 763925 [1] VR8204C3007 Gas Valve (LP Gas), Honeywell 763926 [1] VR8204C3015 ½" Gas Manifold 763927 [1]...
Page 35 HERITAGE E Installation, Operating & Service Manual Service Parts (continued) Part Number [Quantity] Key No. Description HG02E HG03E HG04E HG05E HG06E Hydrostat 3200 Plus w/ sensor 763942 [1] Honeywell S8610M EI Module 763943 [1] 109445-01 - 6/19...
Page 36 Installation, Operating & Service Manual HERITAGE E Service Parts (continued) Part Number [Quantity] Description HG02E HG03E HG04E HG05E HG06E Wrap-around Jacket Panel Not available Jacket Vestibule Panel Top Jacket Panel 763944 763945 763946 763947 Front Door Jacket Panel Tie Bar Jacket Panel...
Page 37 HERITAGE E Installation, Operating & Service Manual Service Parts (continued) Part Number [Quantity] Description HG02E HG03E HG04E HG05E HG06E Supply Water Manifold 763948 [1] Temperature/Pressure Gauge 763949 [1] 30 PSI Safety Relief Valve 763950 [1] Drain Valve Obtain Locally (3/4" NPT boiler connection)
Page 38 Installation, Operating & Service Manual HERITAGE E Service Parts (continued) Part Number [Quantity] Key No. Description HG02E HG03E HG04E HG05E HG06E High Voltage Harness 763958 [1] Low Voltage Harness 763959 [1] Ignition Harness 763960 [1] Accessories: Part Number [Quantity] Key No.
Page 39: Appendix
HERITAGE E Installation, Operating & Service Manual Appendix: Combination Refrigeration/ Heating System A. If boiler is used in connection with refrigeration B. If boiler is connected to heating coils located in systems, boiler must be installed with chilled air handling units where they may be exposed to...
Page 40 Installation, Operating & Service Manual HERITAGE E Appendix: High Altitude Installations (above 2,000 ft .) Installations above 2,000 ft. require conversion kit listed in Table A-2 A-2 High Altitude Conversion Kits Natural Gas Elevation HG02E HG03E HG04E HG05E HG06E (ft .)
Page 41 HERITAGE E Installation, Operating & Service Manual Appendix: Low Return Water Temperatures Thermal Shock: Cast iron boilers are very robust. 110°F and below return water temperatures will not cause thermal shock to cast iron sections. Condensation is a different matter: Cast iron boilers will tolerate intermittent periods of condensation but are not designed for extended condensation periods.
Page 42 Installation, Operating & Service Manual HERITAGE E Appendix: Low Return Water Temperatures (continued) Primary-Secondary Pumping: This is an improvement over simple by-pass piping to reduce condensation. Again this is a fixed system. It can not adapt to variations in temperature and flow.
Page 43 HERITAGE E Installation, Operating & Service Manual 109445-01 - 6/19...
Page 44 Installation, Operating & Service Manual HERITAGE E 109445-01 - 6/19...

This manual is also suitable for:

Hg03e Hg04e Hg05e Hg06e